Clutch Disc: Service and Repair

NOTE: Observe general repair instructions.

CAUTION:
^ Replacement clutch pressure plates are greased and protected against corrosion. Only their friction surfaces are to be cleaned as further cleaning results will lead to corrosion and shorten service life.
^ Assemble the clutch so that the flywheel dowel pin(s) align with the bore(s) slot(s) in the pressure plate, otherwise the TDC marking on the flywheel will be incorrect.
^ Always refer to the engine code and engine number when consulting parts supplier for replacement clutch discs and pressure plates.

NOTE: Remove transmission to perform work on clutch, refer to replacement. Service and Repair





COMPONENT NOTES AND INFORMATION
1 Bolt
- 7 x 40 mm
- Tighten to: 20 Nm (15 ft lb)
2 Flywheel
- Two versions, see below.
- Make sure that dowel pin(s) seat properly
- Clutch lining friction surface must be free of grooves, oil and grease
- Different clutch/flywheel sizes require different clutch housing (timing mark) plugs
3 Clutch disc
- Aligning, refer to procedures below.
- Diameter, refer to Transmission Identification.

WARNING:
^ Friction materials such as clutch linings may contain asbestos fibers.
^ DO NOT create dust by grinding, sanding or by cleaning with compressed air.
^ Avoid breathing asbestos fibers and asbestos dust Breathing asbestos may result in serious diseases and cause injury or death.

4 Clutch push rod
- Grease in area of guide bushing in input shaft
5 Snap ring
6 Release plate
- Lightly lubricate pressure plate contact surface and clutch pushrod socket with G 000 100 grease
7 Attachment bolt, pressure plate to crankshaft
- Removing and installing, refer to Engine
8 Intermediate plate
- Installation position, refer to procedure below.
9 Pressure plate
- Two versions, refer to information below
- Maximum distortion of pressure plate inner surface: 0.20 mm (0.008 inch)
- Replace pressure plate that has damaged or loose rivets.

CAUTION:
^ Pressure plates are treated against corrosion and greased. Only the friction surface must be cleaned.
^ When assembling the clutch make sure that the flywheel dowel pin(s) and the hole(s) or slot(s) in the pressure plate are aligned.

REMOVAL





- Hold flywheel in place with VW 558 retainer.
- Loosen bolts and remove flywheel.
- Remove clutch disc





- Use screwdriver to free ends of snap ring -A- from bores -arrows- and remove.
- Remove release plate -B-.





- Hold pressure plate in place with VW 558 retainer and bolt-A- and remove.
- Remove pressure plate and intermediate plate.

INSTALLATION
- Position pressure plate.
- Position intermediate plate.





- Installation position of intermediate plate:
Protrusion -arrow- points out away from pressure plate
- Install new attachment bolts.
- Hold pressure plate in position with VW 558 retainer as during removal, and tighten attachment bolts.
- For tightening information, refer to Engine.





- Position release plate -B- and attach to pressure plate with snap ring -A-. Lock both ends of snap ring wire in bores in pressure plate -arrows-.
- Coat splines at center of clutch disc with a thin layer of G 000 1000 grease.
- Then move clutch disc back and forth along input shaft until disc hub moves on shaft with no resistance.

CAUTION: Always remove any excess grease.

- Mount clutch and pressure plate to flywheel.





- Place VW 547 clutch pilot disc in position and tighten down flywheel attachment bolts. Alternate in a diagonal pattern to tighten bolts evenly.
- Install VW 558 retainer to flywheel as for removal to tighten flywheel bolts
- Tighten to: 20 Nm (15 ft lb)

Flywheel Versions
- Up to December 1992:
- Two alignment dowel pins
- Dowel pin diameter: 6 mm (0.24 inch)





- From December 1992:
- Flywheel mass increased
- One alignment dowel pin -arrow-
- Dowel pin diameter: 7 mm (0.28 inch)

Clutch Pressure Plate Versions
- Up to December 1992:
- Two recesses mate with flywheel alignment dowel pins to center flywheel





- From December 1992:
- One recess -arrow 1- mates with one flywheel alignment dowel pin
- Circular shoulder -arrow 2- centers flywheel

CAUTION: The later style clutch pressure plate can only be installed together with the later style flywheel.